Method of cutting material



' 21, 1938 6.1. BALF'E METHOD OF CU'I'TING MATERIAL Originai Filed Sept, 23, 1933 9 Sheets-$11681; 1

e. 'r. BALFE ma'niob 9F CUTTING MATERIAL June 21, 1938.

9 Sheets-Sheet 2 Original Filed Sept. 23, 1953 iw ggrm attomegs Julie 21, 1938.

9 Sheets-Sheet s G; '1'. BALF'E) unmon of CUTTING MATERIAL ori mlr'ned Sept 23, 193a June 21, 1938. sir. BALFE 2,121,004

usmon OF CUTTING MATERIAL v original Filed Sept. 25, 19:53 9 Sheets-Sheet 6 June 21', 1938. G. 'r. BALFE mamon' OF cumme MATERIAL Original Filed se a. 25. 1935 9 Sheets-Sheet 7 fle wattomegi June 21, 1 938. G BALFE 2,121,004

' METHOD OF CUTTING MATERIAL Original Filed Sept. 23, 1933 9 Sheets-Sheet 8 3maentor I MJ G M Jun 21, 1938 T 11 BALFE 2,121,004

METHOD OF CUTTING MATERIAL Original File d Sept. 23,1933 9 Sheets-Sheet 9 Zinnentor 5 9 j gagagfm mgg.

2c of the die at the'same time.

' Patented June 21, 1938 UNITED STATES PAT ENT OFFICE I 2,121,004 ammo or come summer.

'1'. Belle, Detroit, Mich, asaignor to Detroit Gasket A, Mfg. (30., Detroit, Mich, a cornotation of Michigan September 18, 1937.

My invention relates to a method of and ma-.

chine for cutting and punching-laminated. and

non-laminatedsheet-like structures. It isespecially applicable inconnectio'n with punchable 5 sheet materials that are diil'icult to penetrate such as those of a hard, dense, thick or heavy character.

More particularly; the invention is useful in a connection with-laminated material including a 10 sheet metal layer, and the punching of gaskets Heretofore, single acting punch presses have been employed and these present a number of 5 objections. In the first place, with single action punch presses, and various types of platen presses now on the market, the cutting die must act simultaneously upon the entire area of the sheet. Hence, the pressure must be applied to all points This requires a tremendous, if not excessive, pressure with correspondingly increased power requirements. The

expense of the power supply for maintaining of.

such high pressures, and the resultant wear upon :5 the machine; is so considerable as to constitute a serious economic factor in the production of gaskets and similar relatively low priced articles where production costs must be carefully watched.

Again, such a single acting press, operated :10 under the high pressures required, results in wear before the trouble is observed by an inspector I and such articles must be rejected. This is par- 4 ticularly the case with articles having varying and difilcult contours such as gaskets and in which accuracy within fine limits is required.

Also, with the customarysingle acting press in which the pressure is applied to all parts of the blank equally ahd simultaneously, it has not been feasible to attempt to work on sheets beyond a definite size limit. This is, of course, due to the tremendous pressure and powerrequired. Moreover, with the single acting machine, usually but 50 one punching operation can'be performed satisfactorlly; and the article must then be subjected to a subsequent punching operation in another machine to complete it. In other words, the punching with a single acting type of machine is limited to a single operation, for example, in cutting a cylinder head gasket, the cylinder centers and the outside trim must be acted upon in another press to out small exhaust and ring gaskets. Likewise, the waste, some of which is of a size to be useful for forming other products, must be separately subjected to a punching operation.

The punching machines now in use are, therefore, limited in the operations which can be performed and the articles cannot be cut and formed in an economic time cycle. The high pressures necessary require excessive consumption of power, and tend to produce wear, particularly on the punching dies, making them short-lived, cutting down production and impairing the quality of the final product.

The present invention accomplishes the punch.- ing and forming operation by applying pressure gradually and continuously over consecutive portions of the die and the sheet material.

That is, the die is operated by a rolling pressure, as distinguished from a force acting simultaneously upon the entire area of the die. This rolling pressure is exerted progressively upon tangential contact portions of the die; hence individual areas of the sheet material are subjected to a continuous punching and forming operation by the rolling engagement. Thus the pressure applied at any point isalong a tangential line and (1) need be only a fraction of that used in a single acting press, resulting in (2) consequent greatly reduced consumption of power.

' The method, therefore, comprises punching and dieing out a sheet material, by gradually applying the cutting instrumentality to the sheet by means of a rolling pressure in a continuous manner to consecutively shear individual portions of the sheet along tangential lines, and controlling the pressure and speed of the rolling contact. The method also comprises disposing the sheet material in a chuck between a flexible and resilient bed plate, on which the sheet rests, and relatively movable cutting knives disposed above the bed iii a practice.

greater than that exerted per unit area by the singie .acting press. I find that in progressively subjecting the individual areas of the sheet material toa rolling pressure in the manner described, that the operation is not limited by the character of the sheet material. For example, gasket material comprising a layer of metal interposed between layers of compressed asbestos is efficiently punched out.

Furthermore, in the case of a cylinder head gasket formed of this heretofore difllcultlyvpunchable material and requiring several operations, I find that all of the openings and the trimming of the gasket are accomplished by a single engagement of the roller andchuck. In other words, the complete final article is formed in one actuation of the machine and no separate treatments are required.

Of equal importance, the useful waste, for example from the cylinder openings of such a head gasket, is simultaneously cut and formed into gaskets of smaller dimension during this same and single actuation of the machine, and need not be subjected to an additional operation.

Also, because of the rolling pressure, and the method and machine of this invention, the area of the blank which may be worked upon is unlimited. For example, I am able to form two or' more complete cylinder head gaskets at each actuation of the machine and I refer to gaskets of this type, because of the numerous operations attendant upon their production and the dimculty of punching the laminated sheet material having a metal core, as described in the Baife patent. At the same time, I am able to form from the waste, the optimum number of smaller dimension gaskets.

In the preferred machine of this invention, the roller is reciprocated by hydraulic means and its speed of contact with the chuck and the cutting of the blanks are susceptible of nice control. The machine is free of vibration and consequent excessive wearing of the parts, and means are provided to prevent any sharp impacts of the cutting knives upon the bed plate of the chuck, such as would distort or cause breakage of the cutting knives. That is,'the smooth actuation furnished by the hydraulic means, the construction of the chuck whereby the throw of the knives is limited,-and the flexible top and bed plates of the chuck enable a clean severing without sharply or abruptlyforcing the knives into contact with the material to be sheared, or the bedplate. The latter being flexible, furnishes a resilient stop forthe knives, enabling them to sever the material cleanly without danger of injury to their extremities.

The speed of production of punched articles by employment of the method and machine of this invention is considerably increased over present This is due (1) to the substantially automatic operation of the machine, (2) to the fact that the size of the material treated is not restricted so that any number of articles may be produced by a single actuation of the machine, and (3) the complete articles are formed by a single actuation of the machine, 1. e. upon each movement of the reciprocation of the roll ing instrumentality. Stated again the present invention permits the production of an increased numberof complete articles by a single actuation and enables the cutting and forming to be accomplished within an economic time cycle.

With the present invention, moreover, varying and dimcult contours are produced, and since individual portions of the sheet material are consecutively treated by the gradual continuous exertion of the rolling pressure, the accuracy of the severing is precise.

In the use of a rolling pressure as included in this invention, the roller at no time comes in contactwith the die and since the throw of the die is controlled and the operation of the 'machine is free from abrupt sharp impacts of the die upon the work or the bed plate and is sub .stantially devoid of vibration, the cutting knives particularly and the machine are long-lived. This is important since stoppage due to wear or breakage is reduced to an absolute minimum and the production of imperfect articles which must be rejected, becomes a negligible factor.

While I have referred above to gasket material of the laminated type having a metal insert, it will be understood that the present invention is applicable to cut and form articles from blank materials which are normally easy to punch, as well as more difilcultly punchable sheet materials. The present invention is advantageous, as will be apparent, in that it enables a considerable saving to be effected as regards the power employed, the wear upon the machine, and increased production of complete finished articles by a single actuation in an economic time cycle.

Referring to the drawings:

Figure 1 is' a side elevation of my improved machine.

Figure 2 is a working plan view thereof and showing the hydraulic means for automatically operating the machine.

Figure 3Vis a sectional view on the final-3 of Figure 1.

Figure 4 is a top plan view of the hydraulic cylinder or ram and the carriage means connected thereto, by which the vpressure roller is reciprocated.

Figure 5 is a sectional view showing in detail the hydraulic cylinder or ram and the manner in which the roller carriage is connected to the movable cylinder.

Figure 6 is a top view of one of the chucks employed.

Figure 7 is a side elevation of the chuck of Figure 6.

Figure 8 is a sectional view of the chuck taken on the line 8-8 of Figure 6.

Figure 9 is a sectional view on the line 99 of Figure 7.

Figure 10 is a top view of a chuck showing in dotted lines a sheet of material of a size to permit formation of two complete cylinder head gaskets therefrom. as well as smaller gaskets from the waste.

Figure 11 is a side elevation of the chuck of Figure 10.

Figure 12 is an end elevation of the chuck of Figure 10.

Figure 13 is a top view partly in section of the interior of the chuckshowing means for guiding the sheet material positioned therein, such means forming a stop at one side of the chuck.

Figure 14 is a detailed sectional view taken on -the line i4-ll of'Figure 13.

Figure 15. is a sectional view of thechuck shown in Figure 6 and Figure 10, and illustrating in detail, the cutting instrumentality and the springs for maintaining the cutter spaced from the bed plate of the chuck and on which the gasket material rests.

' l'igureidisadetailviewshowingthemanner in which th'e roller instnnnentality illmtrated in Figure 3 is adiustabiy mountedupon the roller carriage with rdspect to the chuck. Figure 17- is a detail view showing means for accurately adjusting the roller within very fine limits.

- Figure 18 is a. side elevation partly in section of a modified form of machine.

Figure 19 is a top elevation oi the machine shown in Figure 18. and

Figure 20,is a sectional view taken substantially along the line n-a of Figure in.

General construction The punching machine illustrated in Figure 1 is the preferred form and comprises a base, a chuck fixed on the base, having the cutting instrumentality associated therewith adapted to Ell receive the blank sheet material to be punched.

A roller carriage automatically reciprocated by hydraulic means and carrying a roller is adapted to contactwith and pass over the chuck to depress Figure l, or (b) the chuck passes between the rollers as shown in Figure 18. v The preferred embodiment of the invention Referring to Figure l, the machine comprises a base indicated at It, and a substantially hollow cross head or frame indicated at H. The frame H is supported by the spaced legs i2 of the base,

as shown in Figure 5, being bolted thereto as shown or united in any convenient and rigid manner. The base substantially intermediate the legs I2 is provided with a table portion It, inclined with respect to the horizontal, and to which is detachably secured or fixed as by bolts or inany fdesired' manner, the chuck or bed block ll within which is disposed the material to be punched and with which chuck is associated a movable cutting instrumentality. The details of the. chuck will be later herein described.

The cross frame or crosshead ii is provided with flanges It, as shown, in Figure 8. which extend on opposite sides of the cross head substantially across the same within the distance defined by the space between the legs l2. Supported by the flanges it to depend therefrom and slide on said flanges, is a roller carriage indicated as a whole at it and which is illustrated in detail in Figure 3.

The carriage is provided with angular portions l'l lidably fitting the adjacent correspondingly angular base portions ll of the cross head II and is also provided with flanges ll extending over 7 the flanges it of the cross head, by which the carriage is slidably supported in depending relation upon the cross head. The flanges I. are preferably bolted to the upstanding angular portions ll of the carriage, as shown in Figure 4.

The engagement of the. flanges at: the roller carriage and the flanges I! of the cross head constitutes the principal in fact. the only. actual for supporting the carriage for slidingmovement with relation to the chuck. The provision of these flanges and the engagement between the angular portions ll of the carriage and "of the cross headserves to effectively guide the roller carriage in its reciprocatory movement. A suitable continuous lubricating means,

' as shown, is employed to lubricate the Joint between .the contact surfaces of the respective flanges and angular portions. The importance of so supporting and guiding the roller carriage will be again referred to. However, it will be noted here that the roller carriage is supported with its axis extending in a plane inclined to the horizontal and that there is only a single suspension of the carriage, so that it may slide with a minimum of friction and the contact surfaces of the carriage and cross head are continuously lubricated.

The roller 2| is of appropriate weight and has -a shaft 2| upon which the roller is supported for free rotation by means of the roller bearings 22. 'Theshaft 2| is fixed at its ends in eccentrically mounted normally fixed, but rotatable,"

bushings 23. The shaft is connected to the. bushings to rotate therewith by means of pins 24. The bushings are mounted in the depending trunnion portions 25 of the carriage which comprise a split bearing indicated at'28, having the portion 21 thereof bolted to the carriage by bolts 28. The eccentric mounting of the bushings in the split bearing 26 is best illustrated in Figure II and the bushings are held against rotation by the locking pins 28 movable in recesses 30 in the carriage It, said locking pins having arcuate or inclined portions, whence they may be wedged against the bushing by means of the nuts 3! to fix them against rotation, or loosened thereby 'to permit turning of the bushings.

The bushing 21' at one end of the shaft is provided with gear teeth 32 meshing with a spur gear 33' having a turning portion or shaft 34 adapted to be engaged by a suitable wrench. The face of the bushing .23 is provided with a scale 35 and a.suitable pointer 36 to cooperate therewith is connected to the bearing portion 21. In

this manner, turning of the shaft 34, after the pins 29 have been released, will permit the 'eccentric bushings 23 to be rotated and the extent of rotation definitely determined to adjustably position the roller with relation to the chuck. That is, the roller will be raised or lowered with respect to the adjacent surface of the chuck over which it travels and thereby the distance of "the throw or depression of the cutting knives is regulated. The turning movement of the bushings is precisely controll d by the scale and pointer and hence the cutting action is accurately adjusted for the particular sheet mate- 7 rial and cutting instrumentality utilized. Such accuracy is vital to assure a clean shearingand prevent overthrow. and distortion or breaka e of the knives.

' Theoperation of the carriage The carriage, as stated, is reeiprocated on the cross head or frame Ii and the power forproducing this movement is preferably obtained by means-of a hydraulic system illustrated in F gure 2. The hydraulic system per se is not apart of the present invention, but is illustrated for Purposes of clarification. I Referring to Figures 3.4 and 5, the carriage ll is provided with intermediate transverse webs 52 disposed about the reciprocating cylinder ii of the hydraulic system, but spaced therefrom and connected to said webs and extending thereover are the strap or cap members 52 bolted to the webs at 53. Also bolted to the webs between the straps 52 are thrust bars 54. It will be noted that the webs are spaced a suillcient distance to clear the roller and permit free rotation thereof as shown at-55 in Figure 5. Also, the straps 52, which are bolted to the webs 50, fit in grooves 56 in the cylinder 5|, whereby the carriage is fixedly connected to the cylinder 5| and'will move therewith as the cylinder is reciprocated. It should be noted here that the webs 50 do not contact with the cylinder being spaced therefrom as at 58' and only the portions of the arcuate straps 52 fitting in the grooves 58 engage the cylinder, so that movement of the cylinder will reciprocate the carriage. That is, the carriage is supported by the flanges l5 and I! of the cross head and carriage respectively and guided by their angular portions l1 and i8. The connection between the carriage and the cylinder is, therefore, such that no strain, such as might result from starting and stopping of the machine, ,is translated to the cylinder.

As stated, the carriage is reciprocated by the hydraulic power system illustrated in Figure 2. and this consists of a ram which comprises a pair of fluid lines 51 arranged upon opposite sides of a fixed piston 58, closing the ram at one end. The fluid lines and cylinder are housedwithin the cross head II, as shown. It will be observed that the lines or pipes 51 are of-smaller diameter tharithe cylinder 5| and that afluid space is created therebetw'een indicated at 58. Closing this space 58 at the other end of the ram and forming a bearing through which the cylinder may slide over the respective pipes 51, isa cap bearing 88, threaded to the end of the cylinder.

The cylinder 5| which moves the carriage I8 is supported by the line 51 at opposite sides of the cross head ll, as shownin Figure 5, the line at its outer end on each side of the cross head being flxedly supported upon the cross head by a block 82 bolted to the cross head by bolts 83. The block 62 is provided with a flange 84 fitting in a cooperating groove 85 in each end of the line. It will, therefore, be observed that the fluid lines 51 are rigidly secured in position and supported by the cross-head and that the cylinder 5| is mounted for reciprocating movement upon the lines or pipes 51 and carries in its reciprocating movement the roller carriage l8, whereby the latter is passed to and fro across the chuck. As stated above, this reciprocatory movement does not occasion any perceptible strain upon the cylinder.

Referring to Figure 2, the hydraulic system comprises, oi course, a fluid tank 15 and a motor 16. The speed control valve is indicated at.11 and controls the speed of the carriage across the chuck. Two control valves 18 and 19 are employed, one as a stop run lever for use in emergencies or set-up stops. The other lever is employed to cause the cylinder to stop at the end of its stroke or to reciprocate continuously. In the normal operation of the present machine, the lever 19 will be placed in neutral, so that the machine will continuously reciprocate. The numerals 88 and 8| represent delay valveswhich act to retard the return movement of the cylinder at the end of its stroke. An automatic re-' versing valve 82 operates, in conjunction with the valve 19 when the latteris set for continuous reciprocation of the cylinder and also cooperates alignment.

with the supplemental reversing valve 88. A pair of deceleration valves 84 and 85 are employed, whereby the speed of reciprocation of the cylinder and hence the carriage is controlled as by being slowed down after it passes oi! the chuck and before the limit of the stroke of the cylinder is reached.

Referring to Figures. 1 and 2', the carriage car- I ries an upstanding lug 88 disposed substantially intermediate its ends or at any desired point and which lug engages stops 81 carried upon a sliding bar or rod 88 mounted to have reciprocating movement in the brackets 89 secured to the cross head ll. Also arranged on the bar 88 is a pair of trip members 98, which engage the respective levers 9! of the reversing valve 82. The rod 88 also carries at each of its ends a cam member 82 to operate the respective decelerating valves 84 and 85 In connection with the use of decelerating valves, they not only control the speed of the carriage after it leaves the chuck, but likewise act to cushion any impact resulting when the cylinder reaches the ends of its stroke.

It will be understood that while I prefer a hydraulic system, that any other fluid pressure or mechanical means may be employed which will permit a reciprocatory movement to be imparted to the carriage, and wherein the speed of travel of the carriage, its automatic reversal and the control of its speed over the chuck and between the period when it leaves the chuck and is reversed are provided for. Preferably as much as possible of the hydraulic system is housed with-' discharged from the line 51 through the combined supply and discharge lines A and B. Fluid entering the line 51 through either supply line A or B, passes through the openings 51' adjacent the piston and enters the space 59. :Ihe pressure built up within this space will serve to impart the desired sliding movement to the cylinder and hence to the carriage. The operation of the reversing mechanism with its several control and reversiifg valves will permit an. automatic reciprocation at the desired speed and there is no abrupt or other objectionable vibration action such as would wear the parts or produce mis- The decelerating valves 84 are important, in that they take up or absorb the shock incident to the arrest of the movement of the cylinder and its return at the end of the stroke. Moreover, these decelerating valves slow down the movement of the cylinder and the carriage after the roller has passed oi? the chuck, whereby a sufllcient time will elapse for the material which has been cut and formed to be ejected from the chuck. Also, the delay valves will retard the reversal of movement of the cylinder, as well as the time period before it again contacts with the chuck, so that a new sheet of material may be inserted in the chuck ready for the punching operation.

It will be observed that by the provision of the hydraulic means a substantially automatic time controlled reciprocation of the roller carriage is provided for, which is independent of the chuck. Also, by reason of the automatic actuation of the :i. e., consecutive individual portions of the sheet ment on the cross head I'I and the roller adjustably mounted on the carriage by reason of the eccentric bearings 23, that a uniform pressure will be "applied to all parts of the chuck. Thehydraulic apparatus insures that the speed of travel of the carriage will be uniform over the chuck, and hence thecutting dies will be gradually and continuously depressed to punch out consecutive individual tangential areas of the blank material.

The roller being freely rotatable, and of a weight to exertthe desired pressure, will accomplish the desired depressing-of the cutting knives and insure a clean severing of the blank and the forming of a complete article. Since, as stated, the position of the roller with respect to the chuck is adiustably regulated in a precise manner by the eccentric bearings 23, all danger of injury to the extremities of the cutting knives with resultant distortion and breakage is eliminated, the knives being depressed a sufficient distance by the rolling contact to extend through the blank sheet the exact required distance to procure the com; plete shearing action.

Modified construction In the modified construction shown in Figures 18, 19 and 20, a pair of superposed rolls I00, having their shafts mounted in adjustable bearing blocks I00, are rotated by means of a suitable reversible prime-mover through the intermediate gearing indicated as a whole at IllI and upon each side of the roller system, there is ar*- ranged a fixed conveyor shelf I02 and a tiltable conveyor shelf I03, .the respective shelves being in alignment. The conveyor shelves are preferably of the type having a plurality of rollers I04 and suitable angular guide bars I05. A chuck I4 will be positioned upon the conveyors, the operator standing at one side of the machine and feeding' the chuck through the rolls, whence the punching operation will take place gradually and continuously upon consecutive tangential portions of the sheet, and the chuckwill be discharged with the finished cut-sheet upon the conveyor on the opposite side of the roller system. The operator at that sideof the machine will reverse the direction of rotation of the mils, feed another chuck as described, and will then swing the lever I00 to .rock the tiltable conveyor I03, tilting the chuck which has just been operated on,-upon its pivot I01, whereby the chuck will be inclined, as shown in dotted lines in Figure 20,

and the punched sheet will discharge from the chuck by gravity and be collected on the inclined table I00. At the same time, the-operator will take ne of the sheets I00 and place it in the now empty chuck, reverse the lever I00 and feed the chuck in'proper-sequence and in a similar manner back to the operator on the oppositesidc of the roller system.

It is to be observed that inv the operation of the machine described in Figures 18, 19 and 20,

that the chuck is subjected to a rolling contact between the rollers and that the cutting instrumentalities are, therefore, gradually acted upon to cut the blank sheet in a continuous manner,

along lines tangential to the rollers are progressively treated. i

The chucks In Figures 6 to-15 inclusive, I have illustrated the chucks employed in connection with the machines illustrated in Figures 1 and 18. These chucks are formed of metal; and the fixed parts thereof may be welded together or united by.

rivets or bolts. The chucks comprise two parts, a lower part X and an upper part Y, the upper part of the chuck being of a dimension to slide vertically within the lower part of the chuck, as

shown in Figures 8, l4 and 15.

The lowerC-part of the chuck hasa bottom indicated at I25 and'superp'osed. upon the same and secured thereto in any desired manner, is a substantially coextensive bed plate of flexible and resilient sheetmetal I23. Connected to the bottom are opposed end walls I21, as best shown in Figures 8, l0, l4 and 15, and connected to the end walls, and to the bottom at each comer thereof, is a block I28 extending along the sides of the bottom, as shown in, Figure 10. It will be observed that the ends of the lower part x of the chuck are closed, while each side is open between the blocks I20.

The upper part of the chuck is ada ted to slide vertically within, the lower part ass ated, being guided in its vertical sliding movement by the end walls I21 and the blocks I28 forming corner guides. This upper part Y comprises a rectangular metal frame I29, to which is united by screws or rivets, a top plate I30. This top plate is formed of flexible and resilient metal and constitutes the contact portion of the chuck over which the rolling pressure is preferably exerted.

The frame members I29 at the ends of the chuck are provided with recesses I3I within which are adapted to engage the inwardly projecting extremities of threaded pins I32 mounted in the end walls I21 of the bottom part .of the chuck. The exposed ends of the said 'pins are adapted to engage the closed ends. of the respective recesses -I3I, there being four recesses and four 1 and limiting the upward movement of the upper Part.

Carried by'the top plate I30, and spaced from the frame members I 23 thereof, is the die indicated as a whole at I34. This die will comprise a plurality of cutting knives or rules I35, of a size and material and arrangement to obtain the desired cut-out configuration. Surround- .ing the'cutting rules and also connected to the top plate III, is a layer of cushion material I30 and the lower side of said cushion material is provided wit a layer of rubber I31. The respective layers I Q and I31 are provided with openings I33 through which the cutting knives freely extend and the thickness of the laminated structure is substantially equal to the length of the cutting knives, as shown in Figure 15. .In this connection also, the thickness of the and frame members I20 is substantially equal to the thickness of thelaminated-structure and the length of the cutting knives, so that when the upper portion of the chuck is depressed, the throw of the knives will be limited by the engagement of the bottom of the framemembers I29 with the bed plate I26.

It should be noted that since the top plate I30 is flexible and resilient, it will give slightly under the rolling pressure upon depression of the upper part Y, thereby causing the knives to descend beyond the distance defined by the vertical thickness of the frame I29. This will permit the knives to penetrate entirely through the sheet material and cleanly sever the same. In other words, by reason of the flexible top plate, the flexibility of which is sufllcient to permit it to bend slightly under the rolling pressure, the extremities of the knives will project a very small distance on the opposite side of the sheet. The top plate, as stated, is resilient, so that it is not distorted by the rolling pressure and quickly returns to its normal condition, being preferably formed-of spring steel of the desired character,

selected in accordance with the pressure exerted by the machine.

The provision of the flexible top plate I39 permits use of the machine in practicing my novel method. The flexible element holds in predetermined relative positions the individual dies which serve to form the separate openings in the gasket blank. At the same time, the flexibility of the holding element I39 permits these individual dies to be successively and independ ently forced into the blank to penetrate and shear the same along substantially rectilinear lines perpendicular to the plane of the material. In order to prepare an individual blank for cutting the desired number of separated openings therein, it is simply necessary to position the blank beneath the flexible element I39 which has previously had applied thereto in predetermined relation the desirednumber of cutting dies. These dies are thereafter held by the flexible element against movement in a horizontal plane relative to one another but they may be forced into the material progressively and substantially independently by progressively applying rolling pressure over the top of the flexible element, whereby successive transverse portions of the flexible element are flexed downwardly and the dies thereby successively forced into the gasket blank and shear the same.

The fact that the ends of the knives project through the sheet to the opposite side thereof is effectively cared for by the provision of the flexible and resilient bed plate I26. The metal of the bed plate I26 is preferably of a softer nature than that of the cutting knives. The resilience and flexibility of this sheet and the relativelyslight impact caused by contact of the knives therewith, is negligible in that no wear or breakage will take place with respect to the knives, nor will the bed plate I26 be damaged. It is of a flexibility and resilience to absorb the relatively small degree of impact. I

The die I34 is held in proper spaced relation with respect to the upper part Yet the chuck by means of wedge-shaped members I39 arranged at the ends of the chuck between the frame I29 and the adjacent side of the die, and spacer members I40 disposed at the sides of the upper part of the chuck between the frame I29 and the adjacent side portions of the die, all as shown in Figure 10.

The frame I29 at the ends of the upper part of the chuck is provided with a longitudinally extending recess I4I within which is disposed a locking lever I42. At'one end, the locking lever is bent, as shown at I43,. and provided with an inwardly extending lug I44. Each corner of the frame I29 is suitably recessed as at I45 to accommodate the bent end of the lever and the lug. At its opposite end, each lever is provided with an enlarged end I46 fitting in a recess I having a reduced open end I48. Disposed between the reduced open end of the recess and the enlarged end I46. of the lever, is a spring I49 urging the lever and its enlarged end I 46 outwardly of the upper part of the chuck. The lever I42 is conflned in the recess MI by reason of the engagement of its enlarged end in the recess-I41 and at its. opposite end is held by a bracket I50 secured to the frame I29 and through which the lever may freely slide. Pivotally mounted on one of the side frames of the upper part of the chuck, adjacent each end thereof, is a stop lever or sheet material guide indicated as a whole at I5I. This lever has a reduced end I52 adjacent which is a recess I53 and at its opposite end is provided with an angular bend, indicated at I54. The pivot comprises a bolt I55, threaded into the side frame, carrying a hub I56 upon which the lever rocks. A coil torsion spring I5! is wound-about the hub and has one straight end thereof I58 extended to engage the underside of the top plate I39 and another straight end thereof I59 connected to the lever by being hooked through an opening I69 in the angular portion thereof. As shown in Figure 10, two of these stop or guide levers are preferably employed. In the normal position of the levers I5I, the spring projects the enlarged end thereof downwardly to engage the bed plate I26. Thus, the guide levers substantially close one side of the chuck when the upper and lower parts thereof are projected apart by the springs I33. That is, the stop levers I5I will prevent sheet material from passing ,out of one of the substantially open sides of the lower part X of the chuck. Since the chucks are adapted to be positioned in an inclined plane,. this is important in preventing the sheet material from dropping out of the chuck by gravity. In the normal position of the chuck, illustrated in Figure 14, the lug I44 is forced into contact with the reduced end I52 of the lever-by reason of the spring I49. When, however, the upper part of the chuck is depressed, and the lever rocked on therefrom by gravity. In the simple form of chuck shown in Figure 13, when the lever is in .its upper locked position, as in Figure 8, the

enlarged end I46 of the lever I42 is projected outwardly of the chuck, by reason of the movement of the lever when the contact between the lug I44 and the reduced end of the stop I 5i is relieved. The lower part of the chuck is provided with an enlarged opening I6I and the upper part of the chuck is also provided with an enlarged recess I62, whereby the locking lever may be unlocked by depressing the enlarged ends I46, whereupon the stop levers I5I will fall into the position shown in Figure 14 and the contact between the lug I44 and the reduced end of the guide levers I5I will be resumed. In this conditicn of the chuck, as illustrated in Figure 14, it is ireely and, like the plate, be guided by the.

ready'to receive a sheet oi material to be punched. Referring to Figures 11 and 15, a pair 01' spaced I transversely extending angle irons III are con.-

' fixed, that the reciprocating roller will notabruptly strike the chuck and Jar or detach it' nected to the supporting plate I29. These angle irons iorm transverse guides for the sheet material cooperating with the longitudinal stops III.

. The transverse side edges I 19 of the top plate are-bevelled or inclined, as shown, so that the chuck is easfly insertable between a pair of rollers, as in Figure 18, and in order, when the chuck is through the latter, the two parts of the chuck are each gradually compressed toward each other against the action of the springs I88. Where the' chuck is fixed the movable upper part Y is gradually compressed by the rolling .pressure within the bottom part it against the action of the springs.

In connection with the machine of Figure 1, I preferably associate with the chuck automatic levers I5I by means of the roller 28.

Referring to Figures 6, 7, 8 and 9, the chuck is fixed to the table I3 by clamping bars I'II disposed parallel with the ends of the chuck and having flanges I18 engaging over the flanges I19 on the bottom I25 adjacent the end walls I21 of the lower section of the chuck. The clamping bars are detachably held in position on the table I3 by a pluralityoi' spaced bolts I89, the heads of which are fitted in recesses I8I in the table. The stems of the bolts extend through the bars and the bars are clamped to the table by nuts I82.

Supported at each end of the chuck is a lever I99 fixed to a shaft I9I rotatably mounted on the clamping bar ITI, as shown in Figures 6 and 8.

is connected to a pair of spaced slidably mounted bars I99 at one side of the chuck.

Siidably connected to blocks I28 at each end 0! the chuck and slidable wi the spaced bars I89 and disposed in the rear thereof, is a slotted plate I91 having a right angle slot I99. The

slotted plate is connected to the spaced bars by suitable bolts or rivets at one end of the plate and at its opposite end is connected to the slotted bars and to the connecting block I98 by similar rivets, which serve to connect the bars, the. plate and the block I98 together for simultaneous sliding movement of the bars and plate. As shown in Figure 9, the plate I" is held to the 'block I28 at each end of the lower part of the chuck by a bolt. I99, which engages a flanged member 288. The reduced portion 9i oi the flanged member fits in the slot I9 so that the slotteddefined by the bars, so that they may also slide in Figure 7.

flanged member. It will be understood, .0! course, that a similar construction is provided at the opposite end of the chuck, the twoslide mechanisms and operating means being connected together by the bars I98. It'is to. be observed that all of the slide mechanism, except the slotted plate is carried by the clamping bars Ill and that thesiotted bar to which the spaced bars are connected for sliding movement, is supported on the end blocks I28 oi. the bottom part of the chuck. Connected to the block I95 at each end of the chuck is'a suitable torsion spring 298, the springs exerting equal tension upon the respective blocks and serving to maintain the slide mechanism in the normal position, as shown The slide plate I9l is provided upon the opposite walls of the slot I98 with cam surfaces 298, asbest shown in Figure 8. In this figure, the

enlarged ends I89 of the locking lever I8I are shown as extending outwardly of the chuck and within the slot I98, the stop ISI being in locked position, as indicated in Figure 8 andthe' lug I88 therefore engaging in the recess I58 of the stop lever, and the spring I89 maintaining the locking lever I in its out-thrown position with the enlarged ends I89 exposed.

The normal position of the slotted plate is such that when the locking lever MI is projected outwardly and the stops I9I are locked against the undersurface of the upper part of the chuck, the enlarged end I88 of the locking lever is projected into the slot I98 adjacent to the cam suriaces 298 on the walls oi? the slot and is adapted to be engaged thereby and the lever I retracted to unlock the stop lever IIiI when the slotted plate is moved.

'I'he operation or this automatic mechanism fdr unlocking thestops IISI is best understoodby reference to Figures 6 and 7. In Figure '7, the roll is shown as having left the chuck after completing the punching-operation and has depressed the lug I92, whereupon, by reason or the lever system and ,slide mechanism, the slide plates I91 and spaced bars connected thereto, are moved to the right. Since the stop levers iii are in locked position, as shown in Figure 8, and the enlarged heads I88 of the locking levers proiected outwardly, into the slot I98, movement of the lever system and the slotted plate causes the cam surfaces 298 to engage the enlarged ends 01' the locking lever and move the same inwardly to unlock the stop lever IBI. Both of the stop levers III at eachend oi the chuck are simultaneously unlocked by the sliding movement of the slotted plates I9I and the stop levers drop to their normal position, as shown in Figure 14,, to act as a guide and stop for sheet material inserted in the chuck. In this connection, the space defined by the bars I99 is such as to permit the ready insertion of sheet material therethrough into position to rest on the bed plate of thechuck. The springs 298, one 01' which is expanded and the othercompressed, return the spaced bars, the slotted plates, the lever system and the lugs I92 to normal position, they being unrestricted in their return movement, since the enlarged ends I89 are now retracted out of the slots I98, to normal position with the guide levers IBI unlocked and extending downwardly as in Figure 14.

Operation of the machine I will describe a typical operation of the invention, utilizing the chuck of the automatic chuck is secured to the table .or bed frame I3 of the base and fixed with its longitudinally extending open sides of the bottom part parallel to the bed frame, whereby sheets of material to be punched may be inserted in the chuck and eject or fall by gravity therefrom after the punching operation due to the inclination of the bed frame I3, as shown in Figure 3.

The chuck, of course, has the guide levers II thereof disposed in their downward position, as shown in Figure 14, acting as stops to prevent the sheet material from moving off the bed plate I26 of the chuck. The operator having inserted a sheet of material to be punched, the hydraulic system is actuated and the roller carriage moves on the cross head II to engage the chuck. The initial rolling engagement causes the upper part of the chuck at the end thereof adjacent the roller to be depressed, whereby the cutting rules I35, at that end of the die, are gradually forced downwardly into the sheet. The provision of the flexible top plate I30 permits it to flex or give sufliciently to insure that the knives will go completely through the sheet material and form a clean shear and insures against any horizontal shifting of the dies such as would produce inaccuracies in a gasket. The flexible and resilient bed plate I26 of relatively soft material as regards the knives, will readily absorb without distortion the veryslight impact of the knives therewith- The top plate I30 willlikewise return to normal when the rolling pressure is relieved. The upper part of the chuck being depressed by the rolling engagement against the action of springs I33 carries the dies into engagement with the work and simultaneously the stop levers I5I are rocked on their pivots, due to the downward movement of the upper part of the chuck and move toward the undersurface of the top plate I30. The action of the rolling pressure is, therefore, a gradual shearing of the individual tangential portions of the sheet in a progressive manner and this rolling pressure, while of a degree to assure complete penetration of the knives into the sheet, is but a fraction of that required in a single acting press. As the roller moves over the top plate I30, producing concomitant shearing of consecutive individual portions of the sheet, due to the depression of the upper part of the chuck carrying the dies, the complete rocking of the lever I5I whereby its reduced portion I52 is disengaged from the lug I, will permit the lug to slip into the recess I53 and lock the lever in its upward position, as in Figure 8. The lever at one end of the chuck will first be locked and then as the opposite end of the chuck is depressed the other lever will be similarly locked. The locking of the levers throws the enlarged heads I46 of the levers HI outwardly into the slots I90, as best shown in Figure 6.

The speed of movement of the cylinder 5| is, of course, controlled to regulate the speed of F passage of the roller over the chuck and by means of the decelerating valves 84 and 85, the speed of travel of the carriage and roller is preferably slowed down after the roller leaves the chuck, so as to afford an elapsed time before the roller strikes the releasing lug I92 and releases the stops I 5|, 'suificient for the sheets which have been punched, to be ejected or drop from the chuck by gravity. The sheets preferably drop by gravity and this is made possible by the inclination of the table I3 and the chuck, as well as chuck is negligible.

by the automatic upward retraction of the stop levers I5I to locked position, shown in Figure 8.

The roller having left the chuck, and moving at reduced speed to allow time for the punched sheet to be removed from the chuck, at the end of its stroke engages the lug I92, depressing the same and releasing the guide levers I5I, whereupon the operator inserts another blank sheet jacent the roller, whereby the die is caused to progressively and gradually act upon the sheet, forming another punched article. It will be noted that the only manual operation necessary is the insertion of the sheets in the chuck, since the punched sheets fall therefrom by gravity. If desired, I employ an automatic feeding means as? sociated with the hydraulic mechanism or independent thereof and preferably timed to operate with the movement of the roller, as well as an ejecting means similarly actuated. This automatic feeding and ejecting means is particularly useful where the chuck is mounted in a horizontal plane.

By reason of the presentmethod and machine, I am enabled, referring to Figure 10, to produce, at a ingle contact of the roller and chuck, a plurality of cylinder head gaskets 265, for example,

which require fifty or more punching operations.

The number of articles which may be punched is only limited by the size of the apparatus to accommodatethe sheet material. In connection with Figure 10, I also employ the useful waste and punch it simultaneously with the cutting and forming of the gaskets 205 to produce smaller dimension gaskets indicated at 206.

The operation of cutting and forming is carried out with little or no vibration of the machine, due

to the smooth operation of the hydraulic system and likewise because of the gradual application of the cutting dies to the sheet materiaLthe impact of the dies upon the bed plate of the The absence, therefore, of any abrupt or sharp forces enables the machine to have a longer life and the dies are free from distortion or breakage from external causes. The stroke of the ram and hence the travel of the carriage is easily regulatable and it is to be noted in this connection that the lug I92, associated with the chuck for operating the slide mechanism, is likewise adjustable to vary the time limit within which a formed sheet may be ejected from the chuck before the stop levers I5I are unlocked and moved downwardly to engage the bed plate.

I find that the gradual application of a rolling pressure to move the dies into cutting relation progressively with consecutive portions of the.

sheet, enables delicate contours to be cut accurately and continuously since there is no horizontal shifting of the dies. The pressure em ployed at any one point is of a magnitude equal or greater than that applied at any point of a single acting press, but the total pressure, as well as the total power consumed, is materially less than in the-case of a single acting press.

The bed plate I26 will be formed of fibre; brass,

. or wooden blocks, or it may be of hardened spring steel. I prefer a plate made from steel, tempered to about the same hardness as that of the roller mechanism of the chuck. While I prefer the automatic operating means, in some cases it may be desirable to render the machine manually operable. The treadle and hand-lever are of conventional design and are not shown.

This application is a' division of. my co-pending application, Serial No. 690,740, filed September 23, 1933. l

I claim:

1. The method of forming gaskets from metallic blanks and forming therein a multiplicity of separated openings which comprises positioning a gasket blank upon a bed and beneath a number of resiliently supported cutting dies disposed one within the other, restraining the dies against movement toward and from one another while leaving the same free to enter the metallic material independently of one another, and successively exerting rolling cutting pressure on said dies 2. The method of forming gaskets from metallic blanks and forming therein a multiplicity of separated openings which comprises positioning a gasket blank upon a bed and beneath a number of resiliently supported cuttingdies arranged in the same plane and disposed one within the other, restraining the dies against movement toward and from one another while leaving the same free, to enter the metallic material independently of one another along lines substantially perpendicular to the plane of the material, and successively exerting cutting pressure on said dies.

3. The method of forming gaskets from metallic blanks and forming therein a multiplicity of separated openings which comprises positioning a gasket blank upon a bed and beneath a number of resiliently supported cutting dies, restraining the dies against movement toward and from one another while leaving the same free to enter the metallic material independently of one another, and successively applying roller pressure vto the dies and without direct contact of said roller with said. dies and blank.

4. The method of forming gaskets-from metallic blanks and forming therein a multiplicity of separated openings which comprises positioning a gasket blank upon a bed and beneath a num-.

ber of resiliently supported cutting dies, restraining the dies against movement toward and from one another while leaving the same free to enter the metallic material independently of one another along lines substantially perpendicular'to the plane of the material, and successively applying roller pressure to the dies by a roller constantly maintained in the same horizontal plane. v

5. The method of forming gaskets from metallic blanks and forming therein a multiplicity of separated openings which comprises positioning a gasket blank upon a bed and beneath a number of resiliently supported cutting dies disposed one within the other in spaced relation, restraining the dies against movement toward and from one another while leaving the same free to enter the metallic material independently of one another.

and successively exerting cutting pressure on said dies.

which consists in positioning a gasket blank upon a flat surface and beneath a number of resiliently supported cutting dies surrounded by a substantially plane surface, restraining the dies against movement toward and from one another while leaving the same free to enter the metallic material independently of one another, and successively exerting cutting pressure on said dies and without direct contact of said roller with said dies or blank.

7. The method of cutting metallic gaskets which consists in positioning a gasket blank upon a flat surface and beneath a number of resiliently supported cutting dies surrounded by a substantially plane surface, restraining the dies against movement toward and from one another while leaving the same free to enter the metallic material independently of one another, and succesmovement constantly maintained in the same horizontal plane.

8. The method of cutting metallic gaskets which consists in positioning a gasket blank upon a flat surface and beneath a number of resiliently sively exerting cutting pressure on said dies, by a roller pressure, said roller having a path or- 9.. The method of forming gaskets from metallic blanks and forming therein a multiplicity of separated openings which comprises positioning a gasket blank upon a bed and beneath a number of resiliently supported cutting dies, restraining the dies against movement toward and from one another while leaving the same free to enter the metallic material independently of one another and successively applying cutting pressure to the dies by imparting to the bed and the die with the blank therebetween a movement of translation beneath a pressure roll. I

10. The method of forming gaskets from metallic blanks and forming therein a multiplicity of separated openings which comprises positioning a gasket blank upon a bed and beneath a number of resiliently supported cutting dies, restraining the dies against movement toward and from one another while leaving the same free to enter the metallic material independently of one another, and successively applying cutting pressure to the dies by moving the bed and dies with the blank therebetween between opposed rolls.

11. Method of punching sheet-like structures which comprises subjecting a sheet to a rolling pressure by a roller constantly maintained in the same horizontal plane and gradually and continuously engaging a flexibly and resiliently mounted cutting instrumentality with the sheet disposed below the same, and progressively subjecting the plate members with the sheet therebetween to a. rolling pressure and gradually and continuously engaging a cutting instrumen- 1 o tality connected by one of the plate members with the sheet, and progressively punching consecutive individual portions of the sheet.

13. The method of forming gaskets from metallic blanks and forming therein a multiplicity of separated openings which comprises positionin: a gasket blank upon a bed and beneath a number or resiliently supported cutting dies disposed one within the other and arranged in the 

